U.S. patent number 7,055,631 [Application Number 10/812,577] was granted by the patent office on 2006-06-06 for drill pipe protector.
This patent grant is currently assigned to Western Well Tool, Inc. Invention is credited to Andrew Dale Fuller, Brian Mitchell, Norman Bruce Moore.
United States Patent |
7,055,631 |
Mitchell , et al. |
June 6, 2006 |
**Please see images for:
( Certificate of Correction ) ** |
Drill pipe protector
Abstract
A drill pipe protector having a tubular sleeve that is attached
to a section of drill pipe and resides over the outer diameter of
the drill pipe while moving within an associated well casing or
well hole. The sleeve has low-friction end pads positioned on the
ends of the sleeve to reduce friction between the ends of the
sleeve and the end of an adjacent thrust bearing collar used to
hold the sleeve in place on the drill pipe.
Inventors: |
Mitchell; Brian (Oceanside,
CA), Fuller; Andrew Dale (Redondo Beach, CA), Moore;
Norman Bruce (Aliso Viejo, CA) |
Assignee: |
Western Well Tool, Inc
(Houston, TX)
|
Family
ID: |
32990276 |
Appl.
No.: |
10/812,577 |
Filed: |
March 30, 2004 |
Prior Publication Data
|
|
|
|
Document
Identifier |
Publication Date |
|
US 20040188147 A1 |
Sep 30, 2004 |
|
Related U.S. Patent Documents
|
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
|
10407093 |
Apr 4, 2003 |
6739415 |
|
|
|
10082943 |
Feb 26, 2002 |
|
|
|
|
09805612 |
Mar 13, 2001 |
6378633 |
|
|
|
09473782 |
Dec 29, 1999 |
6250405 |
|
|
|
60114875 |
Jan 6, 1999 |
|
|
|
|
Current U.S.
Class: |
175/325.5;
166/241.6 |
Current CPC
Class: |
E21B
17/1007 (20130101); E21B 41/0078 (20130101); E21B
17/1064 (20130101) |
Current International
Class: |
E21B
17/10 (20060101) |
Field of
Search: |
;166/241.1,241.2,241.7,241.4-241.6
;175/57,65,325.1,325.5,325.6,320 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
|
|
|
|
|
|
|
2083102 |
|
Mar 1982 |
|
GB |
|
WO 95/10685 |
|
Apr 1995 |
|
WO |
|
Primary Examiner: Pezzuto; Robert E
Attorney, Agent or Firm: Christie, Parker & Hale,
LLP
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATION(S)
This application is a continuation of application Ser. No.
10/407,093, filed Apr. 4, 2003, (issued as U.S. Pat. No.
6,739,415), which is a continuation-in-part application of
application Ser. No. 10/082,943, filed Feb. 26, 2002, (now
abandoned), which is a continuation of application Ser. No.
09/805,612, filed on Mar. 13, 2001, (issued as U.S. Pat. No.
6,378,633), which is a divisional application of application Ser.
No. 09/473,782 filed Dec. 29, 1999, (issued as U.S. Pat. No.
6,250,405), which claims priority from U.S. Provisional Application
No. 60/114,875 , filed Jan. 6, 1999.
Claims
What is claimed is:
1. An underground drilling system comprising: a wellbore in an
underground formation; a fixed tubular casing installed in the
wellbore; a rotary drill pipe extending through the casing and
having O.D. spaced from an I.D. of the casing or wellbore during
normal drilling operations; a protective sleeve mounted around the
drill pipe having a hardness in the range of 75 to 123 Rockwell R;
thrust bearing collars rigidly affixed to the drill pipe above and
below the sleeve for maintaining the sleeve in a fixed axially
position on the drill pipe; the protective sleeve mounted to the
drill pipe via an internal sleeve I.D. configuration allowing the
rotary drill pipe to continue rotating within the sleeve at a
rotation rate sufficient to conduct drilling operations in the
formation; said internal configuration comprising longitudinally
extending and circumferentially spaced apart axial grooves formed
in an I.D. wall of the sleeve for allowing fluid to circulate
through a space formed between the I.D. of the sleeve and the O.D.
of the drill pipe; at least one low-friction abrasion-resistant end
pad formed on at least one end of the protector sleeve to reduce
friction between the end of the protector sleeve and an adjacent
end of the thrust bearing collar.
2. The drilling system of claim 1 wherein the sleeve has a
low-friction abrasion-resistant end pad formed on either end of the
protector sleeve.
3. The drilling system of claim 1 wherein the end pad is a single
piece integrally formed with the sleeve.
4. The drilling system of claim 1 wherein the end pad comprises
multiple segments formed in the end of the protector sleeve.
5. The drilling system of claim 1 wherein the end pad is made of
ultra high molecular weight polyethylene.
6. The drilling system of claim 1 wherein the end pad is
mechanically attached to the end of the protector sleeve.
7. The drilling system of claim 1 wherein the end pad has
castellations formed around a perimeter of the end pad.
8. The drilling system of claim 1 wherein the end pad is attached
to a cage embedded in the protector sleeve.
9. The drilling system of claim 1 wherein the protector sleeve has
a soft elastomer liner on the I.D. of the protector sleeve.
10. The drilling system of claim 1 wherein the protector sleeve has
an O.D. including multiple distinct radius external curved
surfaces.
11. The drilling system of claim 1 wherein the O.D. of the
protector sleeve includes at least one low-friction insert.
12. A protective sleeve for installation around a drill pipe used
to drill a wellbore in an underground formation, the protective
sleeve preferentially contacting the I.D. of a well casing or bore
when the drill pipe deflects off center in the casing or bore to
protect the casing or bore from contact with the drill pipe or its
tool joints during rotation of the drill pipe, and which the sleeve
has a generally cylindrical configuration with an internal I.D. for
contact with the O.D. of the drill pipe wherein the sleeve is a
multi-component construction comprising an outer shell and a liner
positioned within the shell wherein the shell has a hardness in the
range of 75 to 123 Rockwell R and is greater than the liner.
13. A non-rotating drill pipe protector for use and the wellbore
comprising: a sleeve sized to be placed around a drill string; said
sleeve having an I.D. having a plurality of grooves for generating
a fluid bearing between the I.D. and the drill pipe; the sleeve
having an O.D. including multiple distinct radius external curved
surfaces contoured for increasing sliding contact surface area,
said contoured surfaces separated by channels on the O.D.; and a
soft elastomer liner having a hardness of 60 Shore A or less on the
I.D. of the sleeve.
14. The protector of claim 13 wherein the sleeve has at least one
low-friction end pad positioned on the end of the sleeve.
15. The protector of claim 14 wherein the end pad comprises
multiple segments formed in the end of the sleeve.
16. The protector of claim 14 wherein the sleeve has a low-friction
end pad positioned on each end of the sleeve.
17. The protector of claim 13 wherein the sleeve has low friction
wear pads on the O.D. of the sleeve.
18. The protector of claim 14 wherein the end pad is made of ultra
high molecular weight polyethylene.
19. The drilling system of claim 9 wherein the liner comprises
multiple strips positioned around the I.D. of the protector sleeve.
Description
FIELD OF THE INVENTION
This invention relates generally to non-rotating drill pipe
protectors attached to a drill string, and more particularly, to
improved low-friction drill pipe protectors by incorporating a soft
elastomer liner and low-friction end pads.
BACKGROUND OF THE INVENTION
The drilling of holes or bores into underground formations and
particularly, the drilling of oil and gas wells, is typically
accomplished using a drill bit which is attached to the lower end
of an elongated drill string. The drill string is constructed from
a number of sections of tubular drill pipe which are coupled at
their ends to form the Adrill string@. The drill string extends
from the drilling surface into a well or Awellbore@ which is formed
by the rotating drill bit. As the drill bit penetrates deeper or
further into an underground formation, additional sections of drill
pipe are added to the drill string.
Casing is generally installed in the wellbore from the drilling
surface to various depths. The casing lines the wellbore to prevent
the wall of the wellbore from caving in and to prevent seepage of
fluids from the surrounding formations from entering the wellbore.
The casing also provides a means for recovering the petroleum if
the well is found to be productive.
A drill string is relatively flexible, being subject to lateral
deflection, especially at the regions between joints or couplings.
In particular, the application of weight onto the drill string or
resistance from the drill bit can cause axial forces which in turn
can cause lateral deflections. These deflections can result in
portions of the drill string contacting the casing or wellbore. In
addition, the drilling operation may be along a curved or angled
path, commonly known as Adirectional drilling.@ Directional
drilling also causes potential contact between portions of the
drill string and the casing or well bore.
Contact between the drill string and the casing and well bore
creates frictional torque and drag. In fact, a considerable amount
of torque can be produced by the effects of frictional forces
developed between the rotating drill pipe and the casing or the
wall of the well bore. During drilling operations, additional
torque is required while rotating the drill string to overcome this
resistance. In addition, the drill string is subjected to increased
shock and abrasion whenever the drill string comes into contact
with the wall of the well bore or, where lined, the casing.
Drilling tools and associated drill string devices encounter
similar problems.
To alleviate these problems, drill pipe protectors are typically
spaced apart along the length of the drill pipe. These drill pipe
protectors were originally made from sleeves of rubber or other
elastomeric material which were placed over the drill pipe to keep
the drill pipe and its connections away from the walls of the
casing and/or formation. Rubber or other elastomeric materials were
used because of their ability to absorb shock and impart minimal
wear.
Previously available drill pipe protectors have an outside diameter
(O.D.) greater than that of the drill pipe joints, and were
installed or clamped rigidly onto the drill pipe at a point near
the joint connections of each length of drill pipe. The O.D. is
specifically sized to be larger than the tool joint, but not too
large as to restrict returning fluids which could result in
Apistoning@ of the protector in the hole. Such an installation
allows the protector only to rub against the inside wall of the
casing as the drill pipe rotates. Although wear protection for the
casing is the paramount objective when using such drill pipe
protectors, they can produce a significant increase in the rotary
torque developed during drilling operations. In instances where
there may be hundreds of these protectors in the wellbore at any
one time, they can generate sufficient accumulative torque or drag
to adversely affect drilling operations if the power required to
rotate the drill pipe approaches or exceeds the supply power
available.
In response to the problems of wear protection and torque build up,
improvements have been directed toward producing drill pipe/casing
protectors from various low-friction materials in different
configurations. However, such an approach again has only been
marginally effective, and oil companies still are in need of an
effective means to greatly reduce the wear and
frictionally-developed torque normally experienced particularly
when drilling deeper wells and deviated wells.
U.S. Pat. No. 5,069,297 to Krueger, et al., assigned to the
assignee of the present application, and incorporated herein by
reference, discloses a drill pipe/casing protector assembly which
has successfully addressed the problems of providing wear
protection for the casing and reduced torque build up caused by the
drill pipe protectors during drilling operations. The protector
sleeve in the '297 patent rotates with the drill pipe during normal
operations in which there is an absence of contact between the
protector sleeve and the casing, but the protector sleeve stops
rotating, or rotates very slowly, while allowing the drill pipe to
continue rotating within the sleeve unabated upon frictional
contact between the sleeve and the casing. Thrust bearings are
rigidly affixed to the drill pipe at opposite ends of the protector
sleeve, and these, in combination with the internal configuration
of the protector sleeve, produce a fluid bearing effect in the
space between the inside of the sleeve and the outside of the drill
pipe. The fluid bearing effect is produced by circulating drilling
fluid through the space between the sleeve and the drill pipe so
that it reduces frictional drag between the rotating drill pipe and
the sleeve when the sleeve stops rotating from contact with the
casing.
U.S. Pat. No. 5,803,193, to Krueger, et al., assigned to the
assignee of the present application, and incorporated herein in its
entirety by reference, discloses a drill pipe/casing protector
assembly which provides an enhanced fluid bearing effect that
reduces frictional drag between the rotating drill string and the
protector sleeve during use.
Although modern drill string protector designs have improved the
lubrication and protection of both the drill string and the casing,
there is still a need for improved sliding lubrication. In
addition, there is a need for hydraulic lift to overcome the heavy
normal forces and torques encountered by the operating drill
string. This problem is especially significant in extended reach
drilling. In long holes and as depth increases, the friction of the
drill string against the hole wall increases resulting in
difficulty in putting weight on the drill bit or a tendency for the
weight to surge forward then reduce in a Astickion@ type process.
Thus, a drill pipe protector that both reduces the torque from the
drill string and increases the sliding ability of the drill string
against the casing is highly desirable.
Another problem to which the present invention is directed is the
reduction of friction between the protector sleeve and the thrust
bearings or collars positioned on either end of the sleeve.
Improvements in economic value through increased product life
without loss of structural integrity is also desirable.
SUMMARY OF THE INVENTION
The present invention overcomes the aforementioned problems by
providing in one embodiment a drill pipe protector assembly that
provides hydraulic lift and improved sliding lubrication to a drill
string. The creation of hydraulic lift and forced lubrication
reduces wear on the protector and on the casing or well wall as
well as reducing sliding friction of the drill pipe/protector
combination relative to the casing or well wall.
By providing a drill pipe protector assembly having a fluid pathway
which directs a portion of the drilling mud moving through the
annular space between the drill pipe protector and the drill pipe
to the annular space between the protector and the casing or outer
well wall, hydraulic lift is created and sliding lubrication is
achieved. By providing shaped channels along the longitudinal
length of the outer surface of the protector, increased hydraulic
lift is developed.
In one embodiment, the present invention is generally directed to a
drill pipe protector which defines a tubular sleeve that fits over
the drill pipe. The sleeve is attached to a section of drill pipe
and resides over the drill pipe. The sleeve is positioned between
the outer diameter of the drill pipe and an associated well casing
or well hole. The sleeve is adapted to provide hydraulic lift and
lubrication relative to the well casing and thus, increase the
proclivity of the drill pipe to slide down the hole while also
reducing the development of cutting dams.
More specifically, the drill pipe protector assembly comprises a
tubular body having an inner surface and an outer surface and
extends along a longitudinal axis between a first end and a second
end. The tubular body is adapted to be deployable about the outside
of a drill string and within the wellbore or casing. A channel is
formed on the outer surface of the body and extends substantially
along the longitudinal axis from the first end to the second end.
The channel directs the flow of drilling fluid between the outer
surface and the inside surface of the casing. An opening extends
radially from the inner surface to the outer surface of the tubular
body. The opening allows the passage of the drilling fluid from the
inner surface to the outer surface.
In this embodiment the protector is a generally cylindrical shaped
tubular body having a plurality of spaced apart channels along its
outer surface. The outer surface includes a plurality of radially
outwardly protruding ridges which extend substantially along the
longitudinal axis. The ridges are spaced apart sufficient so as to
form the described channels therebetween. At least one, and
preferably, all of the channels include an opening which allows the
drilling fluid to pass from the inner surface to within the
channel.
The sleeve includes a plurality of spaced apart radial openings or
diffusor ports which directs a portion of the drilling mud moving
longitudinally through the annular space between the inside of the
sleeve and drill pipe to the annular space between the outside of
the sleeve and the casing or outer well wall. The outside surface
of the sleeve also includes a plurality of shaped channels which
are in communication with these radial openings. The channels
direct the flowing mud to lubricate the outer surface of the sleeve
and create hydraulic lift relative to the casing wall.
In another embodiment of the present invention, the drill pipe
protector assembly is a tubular sleeve having a plurality of
longitudinally extending and radially protruding ridges formed on
its outer surface. The ridges or ribs are spaced apart to define
channels therebetween and at least some of the channels are
configured to define a longitudinally extending channel having a
double wedge shape. The double wedge shaped channels form
passageways for the longitudinal flow of the drilling mud along the
outer surface of the sleeve. Each channel or passageway includes a
radially oriented internal passageway that interconnects the
drilling fluid passing through the annular space between the sleeve
and the drill pipe and the annular space between the outside of the
sleeve and the casing. Each double wedge shaped channel defines an
increasingly narrower and shallower passageway which transitions to
a increasingly wider and deeper passageway along its longitudinal
length. The double wedge shape accelerates and then decelerates the
flow to create a hydraulic lift relative to the casing wall and
also enhance the flow of the drilling mud therebetween.
In another aspect of the present invention, the protector assembly
includes a tubular sleeve for use with drill tool assemblies. The
sleeve includes channels formed on the outer surface for directing
the flow of mud in the annular space between the channels and the
casing. In addition, the sleeve includes a plurality of spaced
apart radially oriented internal passageways that interconnects the
drilling mud passing through the annular space between the sleeve
and the drill pipe and the annular space between the outside of the
sleeve and the casing.
In another embodiment of the present invention, the protector
incorporates low-friction material pads on the external surfaces.
The pads are made of Teflon composites. The protector can have a
plurality of curved surfaces.
In another embodiment of the present invention, the protector
incorporates a multi-stave multi-material sleeve that includes use
of a soft elastomeric liner having a preferred hardness of 60 Shore
A, although can be in the range of 40-85 Shore A, in a urethane
sleeve having a preferred hardness of 95 Shore A, although can be
in the range of 75-95 Shore A for urethane, and 75 to 123 Rockwell
R for harder plastics. The flexible inner liner material produces a
more efficient fluid bearing and thus a lower coefficient of
rotational friction between the drill pipe and the sleeve.
Studies have been undertaken to improve the performance of the
fluid bearing of a drill pipe protector while providing the same or
better strength of previous polyurethane formulations and improving
protector assembly economic life. Testing determined that friction
losses were manifest between the drill pipe and the protector
sleeve on the inside diameter of the sleeve and at the interface
between the sleeve and the collar on the ends of the sleeves and
collars. The combination of these two sources of friction is the
net resultant coefficient of frictional loss per drill pipe
protector assembly. Quantification of the rotational frictional
loss on the sleeve I.D. and the rotational loss at the interface of
the sleeve to the collar varies for different types of materials
used for the protector sleeves.
For urethane sleeves with 95 A Shore hardness, approximately 50 to
60% of the total frictional loss comes from the friction between
the ends of the sleeve and the collar. The frictional loss between
the sleeve I.D. and the drill pipe provides the other significant
friction dissipation. The friction between the ends of the sleeve
and the collar is the source for the wearing of the ends of the
sleeves and, hence, most frequently becomes the factor that limits
the useful economic life of the protector sleeves and collars.
Therefore, in another embodiment of the present invention, the
protector consists of a unique composite sleeve design to reduce
frictional forces and wear on the ends of the sleeves and collars
without loss of structural integrity. This is accomplished by
incorporating low-friction abrasion-resistant end pads integrally
molded into the sleeve during the manufacturing process. The end
pads are pre-stamped into a preferred configuration wherein the
pre-formed low-friction end pad is placed at the bottom of the mold
during the manufacturing process. Depending upon the configuration,
a metal cage would then be inserted before the urethane is poured
into the mold. Low-friction end pads can be positioned at one or
both ends of the protector sleeve during the manufacturing process.
Alternatively, multiple segments of low-friction abrasion-resistant
end pads can be positioned at the end of the sleeve, which are
placed at the bottom of the mold before the urethane is poured.
These and other features and advantages of the invention will be
apparent and more fully understood by those of skill in the art by
referring to the following detailed description of the preferred
embodiments which is made in reference to the accompanying
drawings, a brief description of which is provided below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side elevational view, partly in
cross-section, showing a string of drill pipe having drill
pipe/casing protector assemblies according to this invention
installed between tool joints of the drill pipe in a deviated well
being drilled in an underground formation;
FIG. 2 is a detail view of FIG. 1 illustrating one drill pipe joint
and one drill pipe protector;
FIG. 3A is a front cross-sectional view of a first embodiment of a
hydrolift drill pipe protector assembly constructed according to
the principles of the present invention;
FIG. 3B is a side cross-sectional view of the drill pipe protector
assembly of FIG. 3A, showing diffuser exit ports;
FIG. 4 is a cross-sectional view of an alternative embodiment
hydrolift drill pipe protector;
FIG. 5A is a side view of the protector of FIG. 4;
FIG. 5B is a cross-sectional view of the diffuser of FIG. 5A:
FIG. 6 is a detail view showing different cross-sectional
configurations of the diffuser ports;
FIG. 7 is a perspective view of a wedgelift type drill pipe
protector constructed according to the principles of the present
invention;
FIG. 8 is a partial perspective view of a first alternative
wedgelift type drill pipe protector shown mounted over a section of
drill pipe;
FIG. 9 is a partial perspective view of a second alternative
embodiment of a wedgelift type drill pipe protector shown mounted
over a section of drill pipe and positioned in a section of
casing;
FIG. 10 is a perspective view of a drill pipe tool joint
constructed according to the principles of the present invention
and showing the wedgelift configuration on the external
surface;
FIG. 11 is a partial perspective view of a drill pipe protector
constructed according to the principles of the present invention
and showing a hydrolift type opening and a wedgelift configuration
on the external surface;
FIG. 12 is a side cross sectional view of the drill pipe protector
assembly of FIG. 10 showing the hydrolift ports and the wedgelift
channels on the external surface;
FIG. 13 is a cross-sectional view of a four-sided low-friction
non-rotating drill pipe protector of the present invention;
FIG. 14 is a cross-sectional view of a two-sided low-friction
non-rotating drill pipe protector of the present invention;
FIG. 15 is a partial cross section of a wedgelift type drill pipe
protector incorporation low-friction pads;
FIG. 16 is a partial cross section of a wedgelift type drill pipe
protector incorporating low-friction studs;
FIG. 17 is a perspective view of a drill pipe protector having
single piece low-friction pads integrally molded into the protector
with flexible multi-stave I.D. pads; and
FIG. 18 is a perspective view of a drill pipe protector having
multiple segments of low-friction end pads molded into the
protector with flexible multi-stave I.D. pads.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a well drilling system for drilling a well in an
underground formation 10. A rotary drill string comprises a
plurality of elongated tubular drill pipe sections 12 which drill a
well bore 14 with a drilling tool 15 installed at the bottom of the
drill string. An elongated cylindrical tubular casing 16 can be
cemented in the well bore to isolate and/or support formations
around the bore. The invention is depicted in a deviated well which
is drilled initially along a somewhat straight path and then curves
near the bottom and to the side in a dog leg fashion. It is the
drilling of wells of this type that can substantially increase the
torque applied to the drill string during use, and where the
present invention, by reducing the amount of torque build up, makes
it possible to drill such deviated wells to greater depths and to
drill them more efficiently while preventing damage to the casing
and drill pipe.
The invention is further described herein with respect to its use
inside a casing in a well bore, but the invention also can be used
to protect the drill pipe from damage caused by contact with the
wall of a bore that does not have a casing. Therefore, in the
description and claims to follow, where references are made to
contact with the wall or inside diameter (I.D.) of a casing, the
description also applies to contact with the wall of the well bore,
and where references are made to contact with a bore, the bore can
be the wall of a well bore or the I.D. of a casing.
As illustrated, separate longitudinally spaced apart drill pipe
protector assemblies 18 are mounted along the length of a drill
string to protect the casing from damage that can occur when
rotating the drill pipe inside the casing. The sections of the
drill pipe are connected together in the drill string by separate
drill pipe tool joints 20 which are conventional in the art. The
drill pipe can produce both torque and drill pipe casing wear and
resistance to sliding of the drill string in the hole. The separate
drill pipe protectors 18 are mounted to the drill string 12
adjacent to each of the tool joints to reduce drill string torque,
reduce sliding friction forces, reduce shock and vibration to the
drill string and abrasion to the inside wall of the casing.
When the drill pipe is rotated inside the casing, its tool joints
would normally be the first to rub against the inside of the
casing, and this rubbing action will tend to wear away either the
casing, or the outside diameter of the drill pipe, or its tool
joints, which can greatly reduce the protection afforded the well
or the strength of the drill pipe or its tool joints. To prevent
this damage from occurring, the outside diameter of the drill pipe
protector sleeve, which is normally made from rubber, plastic (such
as nylon) is greater than that of the drill pipe and its tool
joints. Such an installation allows the protector sleeve only to
rub against the casing. Although they are useful in wear
protection, these protectors can generate substantial cumulative
torque along the length of the drill pipe, particularly when the
hole is deviated from vertical as shown in FIG. 1. This adversely
affects drilling operations, primarily by producing friction which
reduces the rotation and torque value generated at the surface and
which is then translated to the drill bit. The present invention
provides a solution to this problem.
FIG. 2 further schematically illustrates a drill pipe protector
assembly of the present invention. Drill pipe protector or sleeve
18 is sandwiched loosely between upper and lower thrust bearings or
collars 22 and 24 which are rigidly affixed to the O.D. of the
drill pipe section 12. A small gap exists between the drill pipe
protector and the thrust bearings. The drill pipe protector is
mounted to the drill pipe using techniques which hold the protector
on the drill pipe and which allow the sleeve to normally rotate
with the drill pipe during drilling operations; but when the drill
pipe protector sleeve comes into contact with the casing 16, the
sleeve stops rotating, or at least slows down substantially, while
allowing the drill pipe to continue rotating inside the drill pipe
protector. This change in point of rotation from the outside
diameter, i.e., O.D. of the protector to the O.D. of the drill
pipe, in effect, reduces the distance at which the friction
associated with drill pipe rotation is applied to the drill
pipe.
Hydrolift Type Drill Pipe Protector
Referring now to FIGS. 3A and 3B, a hydrolift type non-rotating
drill pipe protector 30 is shown.
The hydrolift non-rotating drill pipe protector 30 comprises an
elongated tubular sleeve made from a suitable protective material,
such as, a low coefficient of friction, polymeric material, metal
or rubber material. A presently preferred material is a high
density polyurethane or rubber material. The sleeve has an inside
diameter (I.D.) 32 in a generally circular configuration. The I.D.
further includes a plurality of elongated longitudinally extending,
straight, parallel axial grooves 34 spaced apart circumferentially
around the I.D. of the sleeve. The grooves are open ended in the
sense that they open through an annular first end 34 and annular
opposite second end 36 of the sleeve.
The inside wall of the sleeve is divided into intervening wall
sections between adjacent pairs of the grooves 34. Each wall
section has an inside bearing surface. For polyurethane or rubber
sleeves, a metal reinforcement cage 38 is embedded within the
sleeve between the I.D. wall 32 and the outer diameter (O.D.) wall
40. The metal reinforcing cage 38 has a retainer hinge 42 for
attaching the protector 30 to the drill pipe 12. In the embodiment
shown in FIGS. 3A and 3B the wall thickness of the protector 30
varies between the I.D. and the O.D. so that the protector is egg
shaped in cross section. Located at the base of the egg shaped
protector is a diffuser 44. The diffuser 44 has a plurality of exit
ports 46a 46f which, with the exception of port 46f, extend from
the I.D. 32 to the O.D. 40. The diffuser 44 can be rigidly
connected to cage 38 by fasteners 48 or alternatively can be
integrally molded into the sleeve.
The wall thickness of the protector 30 is such that the drill pipe
protector has an O.D. greater than the O.D. of the adjacent drill
pipe tool joints 20. The annular first 34 and second 36 edges of
the protector sleeve have a configuration that functions to draw
fluid between the sleeve and the collar, thereby assisting in the
formation of a fluid bearing between the I.D. of the protector and
the O.D. of the drill pipe 12. The first edge 34 includes a
generally flat annular inside edge section 50 extending
horizontally and generally at a right angle to the vertical inside
wall of the sleeve. The edge section 50 has a beveled edge section
52 leading to the vertical inside wall to prevent or reduce the
wear to the drill pipe brought about by the action of axial forces.
The angular section 52 works to reduce wear experienced on the ends
of the protector sleeve and the drill pipe when acted upon by heavy
axial loading.
The drill pipe protector sleeve 30 is split longitudinally to
provide a means for spreading apart opposite sides of the sleeve
when mounting the sleeve to the O.D. of the drill pipe. FIG. 3A
illustrates a pair of diametrically opposed vertically extending
edges 54 that define the ends of a longitudinal split that splits
the sleeve into halves. The sleeve is split longitudinally and is
fastened by a latch pin 56 which extends through retainer hinge 42.
Alternatively, the sleeve halves may be hinged along one side and
releasably fastened on an opposite side by a latch pin, or they may
be secured along both opposite sides by bolts. The metal cage 38
forms an annular reinforcing ring embedded in the molded body of
the sleeve. (A protector sleeve made of metal includes no
reinforcing cage). The purpose of the cage is to reinforce the
strength of the sleeve. The cage can absorb the compressive,
tensile and shear forces experienced by the sleeve when operating
in the casing or wellbore. The reinforcing cage can be made from
expanded metal, metal sheet stock, or metal strips or composite
(fiber). One presently preferred technique is to form the
reinforcing member from a steel sheet stock with holes uniformly
distributed throughout the sheet.
The confronting top and bottom thrust bearings or collars 22 and 24
as described in FIG. 2 have adjacent annular end surfaces
confronting the top and bottom annular end surfaces of the sleeve
at essentially the same angular orientations. The upper and lower
thrust bearings 22 and 24 are rigidly affixed to the O.D. of the
drill pipe above and below the drill pipe protector sleeve. The
thrust bearings (also referred to as collars) are metal collars
made of a material such as aluminum, bronze alloys or a hard
plastic material, such as, composites of glass or graphite fibers
in a matrix such as nylon to encircle the drill pipe and project
outwardly from the drill pipe. The collars project a sufficient
axial distance along the drill pipe to provide a means for
retaining the sleeve in an axially affixed position on the drill
pipe, restrained between the two thrust bearings. The thrust
bearings are rigidly affixed to the drill pipe and rotate with the
drill pipe during use. The means for securing the thrust bearings
to opposite ends of the sleeve can be similar to fastening means
shown in U.S. Pat. No. 5,069,297. The upper and lower thrust
bearings are affixed to the drill pipe to provide a very narrow
upper working clearance between the bottom of the upper thrust
bearing and the annular top edge of the sleeve and a separate lower
working clearance between the top of the lower thrust bearing and
the bottom annular edge of the sleeve. The lower clearance can be
narrow, such as one quarter of an inch or a clearance as much as
one inch. The bearings are preferably split and bolted or hinged
and bolted with spaced apart cap screws on outer flanges of the
collar.
During use, when the rotary drill pipe is rotated within the casing
or well, the outer surface of the drill pipe protector sleeve comes
into contact with the interior surface of the casing or wellbore.
The sleeve, which is normally fixed in place on the drill pipe,
rotates with the drill pipe during normal drilling operations.
However, under contact with the inside wall of the casing, the
sleeve stops rotating, or its rotational speed is greatly reduced,
while allowing the drill pipe to continue rotating inside the
sleeve. The configuration of the I.D. of the sleeve is such that
the drill pipe can continue rotating while the sleeve is nearly
stopped or rotating slightly and yet its stoppage exerts minimal
frictional drag on the O.D. of the rotating drill pipe. The inside
bearing surface of the sleeve, in combination with the axial
grooves, induces the circulating drilling mud within the annulus
between the casing and the drill pipe to flow under pressure at one
end of the sleeve through the parallel grooves to the opposite end
of the sleeve. This produces a circulating flow of drilling mud
under pressure at the interface of the sleeve and the drill pipe
and this fluid becomes forced into the bearing surfaces between the
grooves. This deforms or spreads apart the bearing surface regions
to produce a pressurized thin film of lubricating fluid between the
sleeve I.D. and the drill pipe O.D. which reduces frictional drag
between these two surfaces. This action of the lubrication being
forced into the region between the sleeve and the drill pipe acts
as a fluid bearing to force the two surfaces apart, and such action
thereby reduces the friction that would normally be experienced
both on the O.D. of the drill pipe and the I.D. of the sleeve due
to the fact that a thin film of fluid is separating the two
surfaces. Since the fluid separates these two surfaces the torque
developed as a result of the rotation is greatly reduced.
In addition the thrust bearings at opposite ends of the sleeves,
which retain the sleeves position on the drill part, also assist in
producing a further fluid bearing effect at the ends of the
sleeve.
As previously stated pressure is generated by the hydraulic bearing
formed in the space 58 between the O.D. of the drill pipe and the
I.D. of the protector. The pressure is directed to the diffuser
exit ports 46a 46f that delivers fluid to the region between the
protector 30 and the internal surface of the casing 16. The
pressurized fluid tends to exit the diffuser tending to lift the
protector and simultaneously lubricate the interface of the sleeve
to the casing. The fluid movement through the exit ports also tends
to clean cuttings from the bottom of the hole thus helping to
prevent Astuck pipe@ conditions. The pressure at which the
hydraulic bearing fluid exits the diffuser exit ports can be varied
by the speed at which the drill pipe is rotated. For example
rotating the pipe more rapidly increases the pressure thus
improving sliding and lifting of the drill pipe. The number of exit
ports also can be varied to adjust the desired lift. The
geometrical configuration of the exit ports 46a 46f can include
circular, rectangular or other specialized shapes. Although the
exit ports direct fluid in between the outer surface of the
diffuser and the inner surface of the casing, the exit ports can be
placed on the ends of the sleeve to direct fluid towards the collar
to improve life of the collar through reduced loads and improve
lubrication. For example, exit port 46f directs fluid towards the
collar.
The protector 30 incorporates an egg shaped configuration so that
during lateral drilling the diffuser exit ports are always
positioned at the bottom of the hole to lift the drill pipe off of
the casing.
An alternative embodiment hydrolift non-rotating drill pipe
protector 60 is shown in FIGS. 4 and 5. In this embodiment,
protector 60 is eccentric relative to the drill pipe 12 resulting
in less wall thickness near wear pads 62 and a greater wall
thickness at the region near the retainer hinge 63. This
configuration results in a self-positioning of the diffuser 64 at
the lowest portion of the casing 16. Having a thinner area opposite
the hinge 63 also facilitates in opening of the sleeve for
installation onto the pipe. The region near the hydrolift exit
ports 66a 66j thus substantially becomes the portion of the
protector that interfaces with the casing. In this embodiment the
thinner diffuser portion can be made from low-friction material to
improve sliding or alternatively the entire protector can be made
from a low-friction material such as Rulon (Tellon and bronze
composite).
The protector 60 has two types of reinforcements, a metal
reinforcement cage 68 and reinforcement tubes 70. The reinforcement
tubes can run the entire length of the protector or only portions
of its length. The reinforcement tubes may be open to the drilling
mud to aid in returning the mud to the annulus between the
protector and the casing. Alternatively, a portion of the drilling
mud in the reinforcement tubes can be redirected through feeder
tubes 72 to the bearing surface between the I.D. of the protector
and the O.D. of the drill pipe, thus replenishing regions of the
sleeve that deplete fluid through the hydrolift exit ports. The
tubes can be a simple void, or lined with tubing of various types
such as aluminum or composite tubing. When the reinforcement tubes
are properly spaced i.e. 20 80% of cross-sectional area, the
resulting composite sleeve has enhanced bearing resistance.
Protector 60 has an I.D. configuration similar to protector 30
which creates a hydraulic bearing is created by drilling mud moving
between the sleeve and the fluid bearing surface as discussed with
respect to protector 30. A hydraulic bearing is created by drilling
mud moving between the I.D. of the sleeve and the O.D. of the drill
pipe by drilling mud flowing through the axial grooves 74 on the
I.D. of the protector or feeder lines 72 from reinforcement tubes
70.
The placement of the diffuser 64 and exit ports 66a 66j is to allow
the continuous operation of the hydraulic bearing as well as the
operation of the diffuser. It is this combination which provides
the benefits of reduced drilling torque and reduced sliding
resistance. The hydrolift bearings can also be placed on the ends
of the sleeve, pressurized by the thrust bearings, thus providing
additional lubrication as well as some lift-off from the collar
thus increasing the wear life of the ends of the sleeve. Numerous
configurations of hydrolift diffuser and exit port configurations
are possible as shown in FIG. 6., but is not limited to these
configurations, as someone skilled in the art would know.
Configurations 74 and 76 are based upon a thrust bearing principle
whereas configurations 7884 are designed to primarily offer
improved lubrication.
TABLE-US-00001 TABLE 1 HydroLift Design Computations Input Safety
factor 1.1 Fluid Thickness layer for lift 0.01 in Fluid Viscosity
20 cp Fluid Density 9.5 lb/gal Radius of Port 0.1 in Radius of Lift
1 in Lift Required 350 lbs Diameter of Pipe 5 in Length of Section
10 in Eccentricity 0.0625 in Diametrical Clearance 0.012 in RPM 120
rpm Coefficient of side leakage (n) 0.77 Bearing Operation 12
Characteristic (A) Angle between load and 50 deg entering edge of
mud Differential Pressure from Pump 2000 psid Required Pump
Capacity 450 gpm Acceptable Pump Capacity Loss 15% Calculated
Inputs Number of Hydrolift required 5 Fluid Density 0.041
lb/in{circumflex over ( )}3 Eccentricity Ratio (e) 10.417 Ratio of
eccentricity to radial clearance Diametrical Clearance Ratio (m)
0.002 Ratio of diametrical clearance/diameter
Using the hydrolift design computation table recited above, the
benefits of the hydrolift design are seen. For 9.5 lb/gal drilling
mud operating the hydrolift protector on a 5 in. drill pipe and
rotating at 120 rpm, the hydrolift protector provides approximately
350 lbs of lift, thus reducing the normal weight of the pipe at the
sleeve and improving sliding. The benefits of improved lubrication
improve sliding characteristics substantially.
The use of the reinforcement tubes effectively reduces the amount
of material needed to construct the sleeve. Specifically, the
protector shown in FIGS. 4 and 5 use approximately 35% less
material than existing sleeve designs. FIG. 5 illustrates that the
sleeve is approximately twice as long as prior existing sleeves,
however, because of the reduced material used in the hydrolift
protector, the sleeve is only 25% heavier but is 100% longer than
conventional designs. The hydrolift protector can be made from
various materials for different applications. For cased holes, the
hydrolift protector could be a polymer material, using special
low-friction polymers for open-hole designs, or the sleeve could be
coated with a low-friction metal such amorphous titanium.
Configurations for the diffuser design balance the features of
hydraulic lift of the pipe from the casing and the lubrication of
the pipe to the casing. Because lift is provided by pressure,
increasing the lift requires increasing the pressurized area.
Typical hydraulic bearings produce pressure of 10 50 psi per inch
of length for the range of typical pipe diameters. Thus, if the
hydrolift diffuser has a normal area to the pipe of 0.1 sq. in. and
the pressure is 40 psi, the lifting force is 4 pounds. If the area
of the diffuser is increased to 1 in and the pressure remain
constant, the lifting force is 40 lbs. per diffuser. Since a joint
of 5 in. drill pipe typically weights approximately 660 lbs., then
a hydrolift protector with 15 diffusers could effectively reduce
the drill string drag observed at the rig floor.
This is of substantial importance to drilling operations. Because
the normal force resulting from the pipe weight that produces the
wear on the pipe on the casing, the effective weight reduction
facilitates sliding in and out of the hole. The hydrolift protector
provides the lift at exactly the point where it is required thus
maximizing the benefits received.
The second factor of consideration for the hydrolift diffuser is
lubrication. The result of improved lubrication and lift is to
allow the hydrolift protector to act as a hydraulic bearing with
resulting improved sliding friction. Typically protectors have a
sliding friction that is dependent upon the coefficient of friction
between the protector and the casing or formation. For steel casing
and rubber traditional protectors, the coefficient of friction is
between 0.25 0.35. The hydrolift protector of the present invention
provides a lubrication film and hydraulic lift which results in a
coefficient of friction of 0.05 0.1. The result is that ease of
sliding into the hole is achieved. As drill string rpm increases,
the lubrication benefit and the lifting benefit become more
pronounced.
An associated benefit in the hydrolift protector design is hole
cleaning. Typically in ERD wells as the build angle exceeds 55
60.quadrature. cuttings have a tendency to settle out and fall to
the low side of the casing. The result is cuttings dams and many
associated problems. The hydrolift protector design allows the
pressurized fluid to wash away the dams from the bottom of the
casing and back into the fluid stream. Thus three benefits of the
hydrolift protector are provided being lift, lubrication, and hole
cleaning.
Wedgelift Type Drill Pipe Protector
Referring now to FIGS. 7-12 a wedgelift type non-rotating drill
pipe protector is shown in various views and embodiments.
FIG. 7 illustrates a wedgelift drill pipe protector 90 which
preferably comprises an elongated tubular sleeve made from a
suitable protective material, such as, a low coefficient of
friction, polymeric material, metal or rubber material. A presently
preferred material is a high density polyurethane or rubber
material. The sleeve has an inside diameter having a plurality of
elongated, longitudinally extending, straight, parallel axial
grooves 92 spaced apart circumferentially around the I.D. of the
sleeve. The grooves are preferably spaced uniformly around the I.D.
of the sleeve, extend vertically, and are open-ended in the sense
that they open to an annular first end 94 and an opposite annular
second end 96 of the sleeve.
The inside wall of the sleeve is divided into intervening wall
sections of substantially uniform width extending parallel to one
another between adjacent pairs of grooves 92. Each wall section has
an inside bearing surface which can be a curved or a flat
surface.
The wall thickness of the sleeve is such that the drill pipe
protector 90 has an O.D. greater than the O.D. of the adjacent
drill pipe tool joints. The O.D. of the sleeve includes a plurality
of circumferentially spaced apart longitudinally extending,
parallel outer flutes 98 extending from end to end of the sleeve.
The flutes are substantially wider than the grooves 92 inside the
sleeve. Positioned between adjacent flutes 98 are wedge shaped
channels 100. Intervening outer wall sections 102 formed by the
O.D. wall of the sleeve between the flutes and the wedge shaped
channels form wide parallel outer ribs with curved outer surfaces
along the outside of the sleeve.
The wedge shaped channels provide hydraulic lift and improved
sliding lubrication reducing the effective coefficient of friction
between the drill pipe and the casing and increase the proclivity
to slide down the hole. The wedge shaped channel located on the
outer periphery of the sleeve generates a hydraulic bearing between
the sleeve and the casing. Drilling mud is directed to the wedge
shaped channels by the ribs of the outer wall sections 102 into the
increasingly narrower and shallower wedge shaped channel. The outer
ridges provide the dual function of directing the fluid flow and
providing appropriate support for the drill string when at rest.
The width, height and depth of the channel and outer ribs can be
varied based upon the amount of deformation of the tool under
resting loads. The design of the wedge shaped channel and outer
ribs can be adjusted to the required size of pressurized region and
expected loads by varying the width, depth, length and taper of the
channel. The fluid tends to move into the narrowing channel
resulting in a region with elevated pressure, thus lifting and
lubricating the region between the protector sleeve and the casing
wall. Multiple wedge shaped channel configurations can be placed on
the same tool in various configurations such as more than one along
the same line, along multiple parallel lines or along single or
multiple spiral lines.
The wedge shaped channels 100 can be placed in a back to back
configuration as shown in FIG. 7 thus allow the fluid movement
through the channels facing the direction of movement and allowing
drill cuttings to exit from the back side of the sleeve. In
addition placing the wedge shaped channels in a back-to-back
configuration allows reversibility of the tool.
The momentum of sliding into the hole actually helps to continue
the sliding. This is of substantial importance to drilling
operations considering the normal force resulting from frictional
drag resistance of the pipe becomes increasingly greater at greater
depths thus making tripping into and out of the hole increasingly
difficult. Improved lubrication and lift allows the wedgelift
protector to act as a hydraulic bearing with resulting improved
sliding friction. For steel casing and traditional rubber
protectors, the coefficient of friction is between 0.25 0.35. The
wedgelift protector provides a lubrication film and hydraulic lift
thereby reducing the coefficient of friction to between 0.05 0.1.
Another benefit of the wedgelift protector is hole cleaning as
previously discussed with respect to the hydrolift protector.
Referring again to FIG. 7 the wedgelift protector 90 is split
longitudinally to provide a means for spreading apart opposite
sides of the sleeve when mounting the sleeve to the O.D. of the
drill pipe. The sleeve is split longitudinally along one edge 104
which is fastened by a latch pin 106 as is typical in the art. In
this version, the sleeve is simply spread apart along the edge 104
when installed. Alternatively, the sleeve halves may be hinged
along one side and releasably fastened on an opposite side by a
latch pin or they may be secured along both opposite sides by
bolts. A metal cage (not shown) forms an annular reinforcing ring
embedded in the molded body of the sleeve as discussed above.
Top and bottom thrust bearings 22 and 24 as described in FIG. 2
maintain the protector 90 along the length of the drill pipe.
An alternative wedgelift protector 110 is shown in FIG. 8. In this
embodiment the O.D. of the protector is Aegg@ shaped wherein the
wedge shaped channels 112 are positioned on the bottom surface of
the protector. The wedge shaped channels are separated by outer
ribs 114. Flutes 116 are positioned on the top surface of protector
110. The egg shaped protector configuration allows the non-rotating
protector to orient the wedgelift channels on the bottom of the
hole thus properly orienting the protector within the casing. The
protector 110 may also include flow channels 118 to assist in the
return of drilling mud to the annulus between the protector and the
casing.
FIG. 9 illustrates a second alternative embodiment for the
wedgelift protector 120 having an eccentric configuration. As with
the embodiment shown in FIG. 9 the wedge shaped channels 122 are
positioned on the bottom of the protector and are separated by ribs
124. Flutes 126 are positioned on the upper surface of the
protector. In this eccentric configuration the wall thickness is
thinner at the bottom where the wedge shaped channels are located
than at the top where the flutes are located. In this configuration
the design tends to force the wedge shaped channels onto the bottom
of the hole thus properly orienting the protector.
FIG. 10 illustrates the wedgelift concept as incorporated into the
drill pipe tool joint 130. In this embodiment the wedge shaped
channels 132 are milled into a drill pipe tool joint 134. The
wedgelift configuration could be applied to virtually any type of
down hole tool that needs assistance in sliding such as rotating
drill pipe protectors, or integral to drill collars, stabilizers,
drill pipe, or other down hole tools.
FIGS. 11 and 12 show yet another embodiment of the present
invention incorporating both the wedgelift and hydrolift concepts.
The protector 140 is similar to the protector shown in FIG. 7 which
includes a plurality of wedge shaped channels 142 separated by ribs
144 on the O.D. of the drill pipe protector. The protector also
includes a hydrolift exit port 146 extending from the I.D. 148 of
the protector to the wedge shaped channels. Protector 140 is
particularly useful in connection with starting of sliding of the
drill pipe down the hole. As static is typically greater than the
sliding friction, it can be difficult to start the sliding of the
drill string after stopping to make or break a drill pipe joint (or
stand). If the rig has the capability to rotate as well as lower or
raise the pipe, as is frequently the case with rigs with top drive
systems, then rotating the drill pipe will pump pressurized fluid
from the I.D. of the sleeve to the O.D. of the protector. This
pressurized fluid would enter the wedgelift configuration at its
center, providing pressurized lubrication at the exact point of
contact. The combination of fresh and pressurized lubrication would
assist the overcoming of the static friction and assist the
function of the wedgelift in the remainder of the movement of the
drill pipe.
Multi-Sided Low-Friction Slip-Surface Non-Rotating Drill Pipe
Protector
Referring now to FIGS. 1319, multi-sided low-friction slip surface
non-rotating drill pipe protectors are illustrated. FIG. 13
illustrates a four-sided low-friction non-rotating drill pipe
protector 150. As with all the multi-sided low-friction
slip-surface non-rotating drill pipe protectors, protector 150
comprises an elongated tubular sleeve made from a suitable
protective material, such as a low coefficient of friction,
polymeric material, metal or rubber material. A presently preferred
material is a high density polyurethane having a metal reinforcing
cage as previously discussed. Other materials can be a
cage-reinforced rubber of various types including NBR (Nitrile
Butadiene Rubber, hydrogenerated or nonhydrogenated), Aflas
(fluorethylene rubber), with and without additives to improve
performance, in addition to various other types of thermally and
chemically stable plastics may be used. Protector 150 has an inside
diameter in a generally polygonal or a curved shaped configuration.
The I.D. wall 152 includes a plurality of elongated, longitudinally
extending, straight, parallel axial grooves 154. The grooves are
preferably spaced uniformly around the I.D. of the sleeve and
extend vertically from end to end of the sleeve. The metal
reinforcing cage 156 is embedded between the I.D. wall 152 and the
O.D. wall 158.
Protector 150 includes a first section 160 and a second section 162
connected by a hinge 164 at one end and a latch pin 165 at an end
opposite from the hinge 164. Four spaced apart flutes 166, 168, 170
and 172 are spaced around the perimeter and located on the O.D.
wall 158 of the protector. Unlike conventional drill pipe
protectors that typically have an external radius that is
approximately circular with respect to the drill pipe, protector
150 includes an outer surface having four distinct curves that are
designed to contour the common casing size, thus increasing sliding
contact surface area. Each section 160 and 162 includes two sides
174 and 176, and 178 and 180, respectively. By having multiple high
radius external curved surfaces allows more even distribution of
the weight of the drill string through the protector=s sliding
surfaces. A more uniform weight distribution results in more
uniform friction along the sleeve. Each of the four sides 174180
includes low coefficient of friction inserts 182a-h positioned on
the wear areas of the sides. The low coefficient of friction
inserts preferably include the use of a base material of
polyurethane with Teflon bonded to its exterior. Other Teflon
composites, coated aluminum or other low-friction material also
could be used as the insert material. The inserts may be attached
by an adhesive after the sleeve body is molded or inserted during
the molding process. The inserts may contain beveled edges 184 or
holes 186 to create a mechanical bond with the sleeve body. The
inserts can be flush with the O.D. of the protector or can be
raised 0.02 0.03 inches as shown with insert 182g to assist in
wiping of the casing during operation and extend wear life.
More preferably the low coefficient friction inserts are made from
a bronze impregnated Teflon (trade name Rulon 142) having a
coefficient of friction of 0.10 0.12 against steel casing in
drilling mud. As previously discussed the inserts may be held in
place with high-strength high temperature adhesive, by molding into
the urethane, mechanical bonds in the shape of rivets, or by
mechanically connecting the inserts to the metal reinforcement
cage. Preferably the inserts are bonded to the protector as strips
with a typical thickness of 0.090 inches. The surfaces of the
inserts are typically beveled to allow smooth transition between
the inserts and the O.D. wall of the protector. A suitable adhesive
is Tristar TCE211 which has suitable mechanical bonding strength at
elevated temperatures. The Rulon inserts may be reinforced with an
aluminum backing plate that facilitate manufacture and
operations.
An advantage of using bronze impregnated Teflon as the inserts or
other similar material such as glass or graphite filled Teflon is
that the inserts will actually reduce the coefficient of friction
in the casing. As the inserts wear against the casing, they leave
small deposits of bronze impregnated Teflon in the casing.
Therefore, as more and more protectors slide over a particular
torturous portion of the casing, the surface becomes impregnated
into the casing and tends to reduce the coefficient of friction of
subsequent protectors that slide over the region. The use of Teflon
as the inserts also demonstrates the lowest coefficient of friction
on dry or nearly dry surfaces. In instances when the slide loads on
the protector are so significant that the protector wipes the side
of the casing, the Teflon inserts reduces encroachment of the
drilling mud and reduces the coefficient of friction between the
protector and the casing.
FIG. 14 illustrates an alternative low-friction non-rotating drill
pipe protector 190 having a two-sided 192 and 194 low-friction
slip-surface configuration. Protector 190 includes 4 axial flutes
196, 198, 200 and 202. Although the protector 190 is illustrated
with four axial flutes, it is to be understood that other numbers
of flutes such as 2, 6 or 8 are also possible combinations. The
advantage of a two-sided low-friction non-rotating drill pipe
protector is that two sides provide for greater wear surface to be
in contact with the casing.
FIGS. 15 and 16 illustrate the use of low coefficient of friction
inserts in combination with the wedgelift protector previously
discussed. FIG. 15 illustrates protector 210 having low coefficient
of friction inserts 212 positioned adjacent the wedge shaped
channels 214. Also shown in the reinforcement cage 216 embedded in
the protector 210. The ends 218 of the cage 216 are curved over
substantially (up to 200 degrees) by having multiple split sections
around the circumference. The curved end sections allow better
bonding between the sleeve material and the cage, which is
especially useful in sleeves that are sliding within casing as
better gripping between the cage and the protector material is
achieved. Protector 220 shown in FIG. 16 illustrates the use of low
coefficient of friction studs 222 positioned adjacent the wedge
shaped channels 224. A plurality of aluminum studs with amphorous
titanium coatings or other friction reducing coatings can be molded
into the material or physically attached to the cage. The tips of
the studs extend beyond the O.D. of the protector providing a
multiplicity of extensions for the protector to slide upon.
Extended tips can be placed in a variety of arrays that tend to
maximize life and minimize potential damage to the casing.
Alternatively, either bars or plates could be used with the
coatings applied to produce long life low coefficient of friction
surfaces. Other variations could include the use of continuous ribs
or bars of aluminum or similar material instead of short studs. Use
of bars has the advantage of longer surface area, thus fewer
tendencies to damage the casing.
Multi-Component Non-Rotating Drill Pipe Protector
Also shown in FIG. 16 is an alternative materials configuration for
the protector 220. The alternative materials configuration can be
utilized for any configuration protector disclosed herein. Material
226 is a liner which is placed on the interior surface of the
protector 220. Material 228 is placed on the exterior surface of
the protector 220. Material 226 has relatively lower hardness (60
and less Shore A) than the exterior material 228 (90 Shore A). For
example, material 226 is a soft elastomer or rubber having a Shore
A hardness of 60 or less and material 228 is a urethane and has
hardness of 95 Shore A. Material 226 and 228 may be the same
material with different hardness or different materials, such as
polyurethane with different hardnesses resulting from different
amounts of plasticizer. Alternatively, the materials 226 and 228
may be substantially different such as Aluminum for material 228
and rubber for material 226 or a soft elastomer for material 226
and a polyurethane for material 228. Further material 228 can be a
high-strength low-friction high-temperature plastic having a
hardness of 75 to 123 Rockwell R. In this embodiment no metal
reinforcing cage would be necessary wherein the material 228 would
be injection molded and hinges (See FIG. 4) would be integrally
formed. The material 228 can be molded as a hinged cylinder and
have multiple distinct curved surfaces. One skilled in the art can
see the wide range of material combinations that satisfy this
design. The material 226 and material 228 may be chemically bonded,
mechanically bonded, thermally bonded, or various combinations. The
advantage of this design is that the interior material 226 is
capable of flexing around debris caught between the protector 220
and the drill pipe without abrading the drill pipe substantially.
The exterior material 228 with its greater hardness is more
resistant to abrasion between the exterior of the protector 220 and
the casing or borehole wall. Another advantage of having a softer
elastomer for material 226 is a greater fluid bearing performance.
The load carrying capacity of a 60 Shore A elastomer fluid bearing
is at least twice that of a 95 Shore A elastomer fluid bearing of
the same geometry. Friction is also significantly lower in softer
60 Shore A fluid bearings than in harder 95 Shore A fluid
bearings.
A problem with a sleeve that utilizes a soft elastomer is that they
have significantly lower strength, tear resistance, chemical
resistance, and temperature resistance than harder elastomers.
Therefore, a composite sleeve with materials 226 and 228 can obtain
the optimum fluid bearing performance while maintaining high
strength. Material 226 which would be approximately 0.125 to 0.250
inches thick inside material 228, the resulting combination
provides a significant improvement in load carrying capacity and
reduction in friction compared to single component designs in all
operating conditions while maintaining or improving the strength
and toughness of the overall design.
The soft elastomer material 226 would be formed with the polygonal
geometry (i.e., axial grooves), as shown herein, which provides
optimum pressure distribution across the fluid bearing surface
because the surface deforms under the contact load to distribute
the load of the rotating element and maintain fluid bearing
hydrodynamic lift over a greater area. The fluid bearing
performance is directly related to the area and pressure of the
fluid bearing between the rotating drill pipe and the stationary
sleeve. The softer elastomeric materials in the area of the fluid
bearing greatly increases the fluid bearing capability of the
sleeve and seen in more detail in FIGS. 17 and 18. Material 226 can
be a one-piece liner or inserted as several pieces or strips on the
I.D. of the sleeve and seen in more detail in FIGS. 17 and 18.
Material 226 can extend from one end to the other of the sleeve or
only extend through part of the length of the sleeve as shown in
FIG. 16. When the elastomeric liner extends only partially through
the length of the sleeve, it may be necessary to provide a tapered
recess in the harder urethane body to prevent wear of the drill
pipe over that region of the sleeve.
Non-Rotating Drill Pipe Protector with Low Friction End Pads
Quantification of the rotational frictional loss at the interface
of the sleeve and the collar varies for different types of
materials used for the sleeves. For urethane sleeves with 95 A
Shore hardness, approximately 50 to 60% of the total frictional
loss comes from the friction between the ends of the sleeve and the
collar. The friction between the ends of the sleeve and the collar
is the source for the wearing of the ends of the sleeves and,
hence, most frequently becomes the factor that limits the useful
economic life of sleeves and collars. Consequently, the present
invention defines a sleeve configuration that reduces the friction
at the sleeve/collar interface while also improving economic value
through increased product life without loss of structural
integrity. The present invention achieves this objective by
providing a drill pipe protector 300, as shown in FIG. 17, which
incorporates low-friction abrasion-resistant end pads 302
positioned on each end of the sleeve 304. Although the end pads 302
are shown in connection with sleeve 304, it is to be understood
that low-friction abrasion-resistant end pads can be utilized in
connection with any of the sleeve designs disclosed herein.
End pads 302 are a single piece that is integrally molded into the
sleeve 304 during the manufacturing process. The end pads 302 are
pre-stamped into the preferred configuration that includes
castellations 306, which allow fluid to pass from the I.D. of the
sleeve/drill pipe interface and over the end of the sleeve and
collar interface, thus assisting with lubrication and cooling and
reducing wear, as previously discussed herein. For use in
connection with a polyurethane sleeve, during manufacturing the
pre-formed low-friction end pad is placed at the bottom of the
mold, and the inner cage (FIGS. 13 and 14) are placed in the mold
on top of the end pad. The cage can prevent the flotation of the
end pad during molding or can be mechanically attached to the cage
by rivets, or other mechanical interlocking components commonly
known in the art. Protector 300 can have only one low-friction end
pad 302 positioned on the sleeve 304 or can have a second end pad
added during the manufacturing process, resulting in an end pad
positioned at either end of the sleeve 304. Factors, such as
manufacturing cost, economic life, and application, can dictate
whether one or two end pads are incorporated into the protector
300.
FIG. 18 illustrates another embodiment protector 400 wherein
multiple segments of low-friction abrasion-resistant end pads 402
are placed at the ends of the sleeve 404. In this configuration,
instead of having a single integrally formed end pad, as shown in
FIG. 17, multiple individual segments which together form the end
pads would be placed at the bottom of the mold, and the
polyurethane or other plastic would be poured around the pads to
position it in the sleeve. For both embodiments shown in FIGS. 17
and 18, the preferred low-friction abrasion-resistant end pad
material is an ultra high molecular weight polyethylene averaging
3.1 to 6 million molecular weight compliance with ASTM 4020-81
standards. This material is non-abrasive, has a low coefficient of
friction less than 0.2, is 600% more abrasion-resistant than steel,
has no notch sensitivity or cold embrittlement (155F to +200F). The
ultra high molecular weight polyethylene is available under various
trade names, including Ultra Fend by UltraPoly Corporation.
Ultra-high molecular weight polyethylene is available in various
shapes and sizes that can be utilized for the end pads of the
sleeves. The material can be available as rings with the
appropriate diameter of the sleeve, which then would be stamped to
include the surface features of castellations 306, and the bottom
surface that interfaces with the cage. The bottom surface can
include flanges 308 to provide the mechanical locking feature with
the cage and the poured polyurethane sleeve 304. Alternatively, the
end pads for either embodiment may be stamped from flat sheets of
material. By way of example, the sleeve shown in FIGS. 17 and 18 is
made of polyurethane also having low friction side pads 310 and
410, respectively, which could be made of Rulon or the ultra high
molecular weight polyethylene material used for the end pads. The
inside surface 312 and 412 can include a soft elastomer liner, as
discussed with respect to FIG. 16. Similarly, any of the other
features disclosed herein can be incorporated into the protector,
such as hydrolift ports, wedgelift channels, or a plurality of
curved surfaces around the outside diameter of the sleeve.
Similarly, the sleeve can be made of rubber or metal, which
incorporates the low-friction end pads.
Although the present invention has been discussed with various
embodiments thereof, it is to be understood that it is not to be so
limited since changes and modifications can be made which are
within the full intended scope as hereinafter claimed.
* * * * *